MoldMaking Technology's Most-Viewed Case Studies of 2023

Photo Credit: Zero Tolerance LLC (top left), EOS GmbH (top right), Jingdiao North America Inc. (bottom left) and CDM Tool & Mfg. Co. (bottom right)

MoldMaking Technology publishes monthly case studies that offer detailed insights into the real-world application of various technologies and solutions in the moldmaking industry. Each case study typically follows a format that presents:

A problem: The specific challenge or issue faced by a moldmaking shop.
A solution: The technology, process, or strategy implemented to address the problem.
The results: The impact and benefits achieved by implementing the solution, including quantifiable metrics like cost savings, reduced lead times, improved quality, etc.

Take a look at our most-viewed case studies from 2023 — perhaps one of these problems may resonate with your own shop:

5. Five-Axis Vertical Mill Increases Mold Shop Capacity by Reducing Setups

Photo Credit: Zero Tolerance LLC

Zero Tolerance LLC, founded in Kansas in 2011 and later moved to Michigan, specializes in creating molds and injection molding services. In its pursuit of growth while constrained by limited space and budget, the company is strategically expanding capacity. In 2021, it sought a new five-axis CNC mill to enhance capabilities, aiming for versatility, precision, and the ability to work with larger blocks essential for mold production. In short, Zero Tolerance wanted a machine that could do it all while still being compact enough to fit in limited floor space. Read the full article.

4. Large Hybrid Steel Insert Solves Deformation, Dimensionality, Cycle Time Problems

Linear AMS, a company that originated in 2003 as a toolmaker and molder, swiftly adopted metal additive manufacturing (AM) early in its journey. By 2005, it acquired a direct metal laser sintering/solidification (DMLS) printer from EOS North America, marking a pivotal point in its operations. With expertise in designing and printing metal components for molds, Linear became a go-to provider for aerospace companies, producing conformally cooled and heated mold parts.

Photo Credit: EOS GmbH

Over nearly two decades, the team at Linear AMS have honed their skills in crafting and producing core and cavity inserts, lifters, and slides for injection and compression molds using both additive and subtractive manufacturing methods. This extensive experience has led them to cultivate specific preferences and creative techniques that harness the advantages offered by both approaches. Read the full article.

3. Five-Axis Graphite Mill With Automation Debottlenecks Electrode Machining

Photo Credit:Jingdiao North America Inc.

Preferred Tool of Hugo, Minnesota, a full-service mold builder, was facing a bottleneck in electrode cutting that was slowing down mold production and reducing shop productivity. To address this issue, the company invested in a purpose-built five-axis graphite mill from Jingdiao with an automation package. The results were impressive: the mill cut electrodes faster with greater detail, reducing setups, cutting and burning time, material use and electrodes needed per job. The mill was installed in April 2022 and has been running at high spindle speeds of 32,000 rpm, as graphite is brittle, not hard, and high-speed machining produces better results with small cutting tools. Read the full article.

2. True Five-Axis Machine Yields More Throughput, Greater Productivity

CDM Tool & Mfg. Co. LLC, a Wisconsin-based injection molding toolmaker, was facing a growing demand and a limitation in shop capacity. To address this, it sought out a new CNC machining center aiming to streamline operations and boost production capabilities. Despite having various milling machines, including 3+2-axis and four-axis mills, the goal was to minimize setups, leading them to target a genuine five-axis machine.

Photo Credit: CDM Tool & Mfg. Co.

The company’s criteria was strict: Itrequired high-speed precision and consistency, essential for maintaining its reputation for punctual deliveries and stringent tolerances. The new machine also needed to operate autonomously during nights and weekends. Considering the diverse sizes of blocks they work with, a spacious work area was a priority, allowing for efficient machining of multiple smaller components simultaneously. Additionally, since CDM works with both aluminum and steel, versatility was crucial;CDM needed a mill capable of handling both materials for different stages of finishing. Read the full article.

1. CAM Automation Increases Mold Production, Quality

At Machining Technology in Brooklyn Park, Minnesota, the programming team in the mold department had been proficiently relying on a CAM software package for many years. However, fresh programming approaches appeared too advantageous to overlook.

Photo Credit: Open Mind Technologies

Upon joining Machining Technology as vice president, Miguel Aponte aimed to enhance the mold department's efficiency and quality. Evaluating various areas like processing times and part quality, he targeted a change in CAM software, singling out hyperMILL from Open Mind Technologies. Initially met with skepticism due to established programming habits, the team’s transition to hyperMILL ultimately proved worthwhile, revealing substantial benefits without requiring a leap of faith. Read the full article.